Container member, method of manufacturing the same, and display device having the same

ABSTRACT

A display device that includes a display panel and a container member that accommodates the display panel, where the container member can effectively absorb an external impact to sufficiently protect the display panel from damage and minimize deformation caused by an external stress, a method of manufacturing the same. The container member includes a metal frame including a space that accommodates the display panel, a plurality of sides and a bottom having a first opening; and a mold frame arranged between the sides of the metal frame and sides of the display panel. The display device may also include a buffer tape within the first opening. The mold frame is preferably produced by an injection molding technique.

CLAIM OF PRIORITY

This application claims the benefit of Korean Patent Application No.2009-0110910, filed Nov. 17, 2009, the disclosure of which is herebyincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

A container member for accommodating a display panel that caneffectively absorb an external impact to sufficiently prevent the impactfrom reaching the display panel within while minimizing deformationcaused by an external stress, a method of manufacturing the same, and adisplay device having the same.

2. Description of the Related Art

Display devices are generally sorted into cathode-ray tube displaydevices and flat panel display devices. Flat panel display devices havereplaced cathode ray tube display devices due to their light weight andthin thickness. Typical examples of the flat panel display devicesinclude liquid crystal display devices (LCDs) and organic light emittingdiode display devices (OLEDs). In comparison with the LCDs, the OLEDshave excellent brightness and viewing angle characteristics and requireno backlight, so that the OLEDs can be realized as ultra thin displaydevices. The OLEDs are display devices using a phenomenon that electronsand holes injected into an organic thin film from a cathode and an anodeare recombined to form excitons, and thus light having a specificwavelength is emitted by the release of energy resulting fromde-excitation of the excitons.

Particularly, flat panel display devices are frequently used for smallportable display devices such as mobile phones, personal digitalassistants (PDAs), and portable multimedia players (PMPs) in addition tolarge display devices such as televisions and monitors for computers.Since display panels used in the flat panel display devices to display apredetermined image are made of a fragile material such as glass, thedisplay panels are accommodated in separate container members to protectthe display panels from being damaged or deformed by external impact orstress such as drop impact. Such container members generally include ametal frame or a mold frame. The metal frame can prevent the displaypanel from being deformed by external stress owing to its high rigidity,however, the metal frame may damage the display panel in an assemblyprocess upon external impact. To sufficiently absorb the externalimpact, the metal frame must be sufficiently thick, and thus its entiresize is increased. In comparison with the metal frame, the mold framefacilitates the assembly process, and can minimize a size of the displaydevice. However, due to lack of rigidity, the mold frame does notsufficiently prevent the display panel from being deformed by theexternal stress. What is therefore needed is a container for a displayapparatus that is not too bulky, is less apt to damage the displayapparatus during assembly and that adequately protects the displayapparatus from damage due to external impact.

SUMMARY OF THE INVENTION

Aspects of the present invention provide a container member foraccommodating a display panel, which can change its structure to preventdamage to the display panel in an assembly process, and effectivelyrelieve an external impact to sufficiently prevent deformation caused byan external stress, a method of manufacturing the same, and a displaydevice having the same.

According to one aspect of the present invention, there is provided adisplay device that includes a display panel and a container member, thecontainer member includes a metal frame including a space thataccommodates the display panel, a plurality of sides and a bottom havinga first opening and a mold frame arranged between the sides of the metalframe and sides of the display panel. Each of the sides of the metalframe may include at least one fastening aperture, the mold frame mayinclude a plurality of sides, each of the sides of the mold frame mayinclude at least one first protrusion arranged at a location thatcorresponds to the fastening aperture. Each of the sides of the metalframe may include at least one step, the mold frame may include aplurality of sides, each of the sides of the mold frame may include atleast one second protrusion arranged at a location that corresponds tothe step. The metal frame may also include a plurality of roundedcorners. Each of the corners may have a curvature. Each of the sides ofthe metal frame may have a hemmed structure. The mold frame may alsoinclude a bottom having a second opening having an area that correspondsto the first opening. The display device may also include a buffer tapearranged within the first opening of the metal frame.

According to another aspect of the present invention, there is provideda method of manufacturing a container member that accommodates a displaypanel, the method including providing a metal frame having a bottom anda plurality of sides, the bottom having a first opening and forming amold frame on inner sides of the metal frame by injection molding. Themethod may also include forming at least one fastening aperture in eachof the sides of the metal frame and forming at least one protrusion oneach side of the mold frame at a location that corresponds to thefastening aperture during said injection molding. The method may also toinclude forming at least one step in each of the sides of the metalframe and forming at least one protrusion on each side of the mold frameat a location that corresponds to the step during said injectionmolding. The method may also include rounding corners of the metal frameprior to said formation of the mold frame. The method may also includeproducing a hemmed structure by folding the sides of the metal frameprior to said formation of the mold frame.

According to still another aspect of the present invention, there isprovided a display device that includes a display panel to display animage, a metal frame including a space that accommodates the displaypanel, a plurality of sides and a bottom having a first opening, a moldframe arranged between the sides of the metal frame and sides of thedisplay panel and a buffer tape arranged within the first opening of themetal frame. The metal frame may include at least one fastening aperturearranged in each of the sides, and the mold frame may include at leastone first protrusion arranged on each side thereof to correspond to thefastening aperture. The metal frame may include at least one steparranged in each of the sides, and the mold frame may include at leastone second protrusion arranged on each side thereof to correspond to thestep. The metal frame may include rounded corners. The sides of themetal frame may have a hemmed structure. The mold frame may also includebottom having a second opening having an area corresponding to the firstopening. The display device may also include a double-sided tapearranged between the display panel and the bottom of the metal frame.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention, and many of the attendantadvantages thereof, will be readily apparent as the same becomes betterunderstood by reference to the following detailed description whenconsidered in conjunction with the accompanying drawings, in which likereference symbols indicate the same or similar components, wherein:

FIG. 1 is an exploded perspective view illustrating a display deviceaccording to a first embodiment of the present invention;

FIG. 2A is a cross-sectional view taken along line A-A′ of FIG. 1;

FIG. 2B is a cross-sectional view illustrating a modification of acontainer member in display device according to a first embodiment ofthe present invention;

FIG. 3A is an exploded perspective view illustrating a display deviceaccording to a second embodiment of the present invention; and

FIG. 3B is a cross-sectional view taken along line B-B′ of FIG. 3A.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the present embodiments,examples of which are shown in the accompanying drawings, wherein likereference numerals refer to the like elements throughout. In thedrawings, the thicknesses of layers and regions may be exaggerated forclarity. The embodiments are described below in order to explain thepresent invention by referring to the figures.

FIRST EMBODIMENT

Turning now to FIGS. 1 and 2A, FIG. 1 is an exploded perspective viewillustrating a display device according to a first embodiment and FIG.2A is a cross-sectional view taken along line A-A′ of FIG. 1. Referringto FIGS. 1 and 2A, the display device according to a first embodimentincludes a display panel 100 for displaying a predetermined image, acontainer member 200 including a metal frame 210 which provides a spacefor accommodating the display panel 100, metal frame 210 having a bottom211 with a first opening 210 a, a mold frame 220 located inside themetal frame 210, and buffer tape 300 located inside the first opening210 a of the metal frame 210. The display panel 100 may be an organiclight emitting diode (OLED) display panel having OLEDs.

The display device according to a first embodiment may further include apolarizer 400 located on one side of the display panel 100 in order toimprove a contrast ratio and luminance of an image displayed by thedisplay panel 100, and a double-sided tape 500 interposed between thedisplay panel 100 and the buffer tape 300 and between the display panel100 and the bottom 211 of the metal frame 210 of the container member200 in order to firmly maintain adhesion among the display panel 100,the container member 200, and the buffer tape 300.

In the container member 200 of the display device according to a firstembodiment, the metal frame 210 serves to maintain a geometry of thecontainer member 200, thereby preventing an external stress generated byan external impact such as a drop impact from being transmitted to thedisplay panel 100. The mold frame 220 is interposed between sides 212 ofthe metal frame 210 and the display panel 100, and the degree of theimpact on the sides 212 of the metal frame 210 is attenuated oreliminated by the mold frame 220, protecting the display panel 100inside.

The container member 200 may include at least one first fastening hole213 located in each side 212 of the metal frame 210 and at least onefirst protrusion 223 located on each side of the mold frame 220 atlocations that correspond to the first fastening holes 213 such that themetal frame 210 may be firmly coupled to the mold frame 220. Thecontainer member 200 may also include at least one first step 214located at each side 212 of the metal frame 210 and at least one secondprotrusion 224 located on each side of the mold frame 220 at locationsthat correspond to the first steps 214 to more firmly maintain acoupling force between the metal frame 210 and the mold frame 220.Specifically, the steps 214 of the metal frame 210 are located atcorners of the metal frame 210 so that the metal frame 210 can be firmlycoupled with the mold frame 220 regardless of a direction of theexternal impact applied to the metal frame 210.

In the display device according to a first embodiment, the containermember 200 can be assembled by forming the metal and mold frames 210 and220 separately and then coupling the metal and mold frames 210 and 220together. When the metal and mold frames 210 and 220 are in closecontact with each other, it is possible to more effectively protect thedisplay panel 100 from impact and stress caused by the external impactsuch as a drop impact. To best form this close contact between the metalframe 210 and the mold frame 220, the metal frame 210 may first beproduced, and then the mold frame 220 is formed inside the metal frame210 by injection molding to complete assembly of the container member200.

Here, one or both of the first fastening hole 213 and the first step 214are formed in each side of the metal frame 210, and then the mold frame220 is arranged inside the metal frame 210 by injection molding. Byforming the container member this way, the metal frame 210 can be morefirmly coupled with the mold frame 220.

Turning now to FIG. 2B, FIG. 2B shows a cross section of a displaydevice according to a variation of the first embodiment of the presentinvention. In the container member 200 of FIG. 2B, the sides 212 of themetal frame 210 are folded in an inward direction, and thus have ahemmed structure, so that it is possible to further reinforce rigidityof the metal frame 210.

In the scenario where mold frame 220 is produced via a separate processand is then fastened to the metal frame 210 of FIG. 2B where the sides212 of the metal frame 210 have the hemmed structure, an unnecessaryspace may be generated between the metal frame 210 and the mold frame220 due to the hemmed structure. Consequently, it is preferable that themold frame 220 is produced by injection molding when the metal frame 210has sides 212 having a hemmed structure as in FIG. 2B.

Table 1 below shows the results of performing a drop test on the displaydevice including the container member 200 having the metal frame 210 andthe mold frame 220 located inside the metal frame 210, and particularlya structure (Type 1) in which the first opening 210 a is formed in thebottom 211 of the metal frame 210, and thus the buffer tape 300 islocated inside the first opening 210 a, and a structure (Type 2) inwhich the first opening 210 a is not formed in the bottom 211 of themetal frame 210, and thus the buffer tape 300 is interposed between thebottom 211 of the metal frame 210 and the display panel.

TABLE 1 Deformation Jig Rigidity Jig Drop Result Type 1 60.0 33.5 93.5Type 2 40.5 32.5 73.0

Here, a deformation jig for testing a degree of deformation and arigidity jig for measuring a degree of damage caused by an impact wereused for the drop test of the display device. A front drop and a bottomdrop were each carried out ten times, and the score was given within arange of 0 to 5 points according to the degree of deformation or damage.

Referring to Table 1, the structure (Type 1) in which the first opening210 a is formed in the bottom 211 of the metal frame 210 got arelatively high score compared to the structure (Type 2) in which thefirst opening 210 a is not formed in the bottom 211 of the metal frame210. Thus, it could be concluded that the structure (Type 1) in whichthe first opening 210 a is formed in the bottom 211 of the metal frame210 relieved the external impact and stress in a relatively effectivemanner.

More specifically, in the case where the first opening 210 a is notformed in the bottom 211 of the metal frame 210, i.e. in the case inwhich the bottom 211 of the metal frame 210 is located at a regioncorresponding to the display panel 100, the bottom 211 of the metalframe 210 vibrates upon external impact, thereby causing resonance withthe buffer tape 300 located between the bottom 211 of the metal frame210 and the display panel 100, and thus exacerbating the impacttransmitted to the surface of the display panel 100. For this reason,the structure (Type 2), in which the first opening 210 a is not formedin the bottom 211 of the metal frame 210, fails to efficiently relievethe external impact compared to the structure (Type 1) in which thefirst opening 210 a is formed in the bottom 211 of the metal frame 210.

Consequently, the display device according to a first embodimenteffectively absorbs and relieves the external impact using the containermember having a space to accommodate the display panel and having ametal frame having the first opening formed in its bottom and the moldframe located between the metal frame and the display panel, therebyminimizing the deformation caused by the external stress.

Further, the display device according to a first embodiment isconfigured such that the buffer tape is located inside the first openingof the metal frame, and thus an entire thickness of the display deviceis reduced by a thickness of the bottom of the metal frame. As a result,the presence of the first opening 210 a in the bottom 211 of the metalframe 210 serves not only to protect the display panel 100 within butalso to reduce the total thickness of the display device.

SECOND EMBODIMENT

Turning now to FIGS. 3A and 3B, FIG. 3A is an exploded perspective viewillustrating a display device according to a second embodiment of thepresent invention and FIG. 3B is a cross-sectional view taken along lineB-B′ of FIG. 3A. Referring to FIGS. 3A and 3B, the display deviceaccording to a second embodiment includes a display panel 100 fordisplaying a predetermined image; a container member 600 including ametal frame 610 having a space that accommodates the display panel 100and having a bottom 611 with a first opening 610 a, and a mold frame 620located inside the metal frame 610, and a buffer tape 300 located insidethe first opening 610 a of the metal frame 610.

Similar to the aforementioned display device according to a firstembodiment, the display device according to a second embodiment mayfurther include a polarizer 400 located on one side of the display panel100, and a double-sided tape 500 interposed between the display panel100 and the buffer tape 300 and between the display panel 100 and thebottom 611 of the metal frame 610. The display panel 100 may be an OLEDdisplay panel having OLEDs.

The container member 600 is formed in such a manner that corners of themetal and mold frames 610 and 620 are chamfered, preferably rounded, tohave a predetermined curvature. Here, the container member 600 of thedisplay device according to a second embodiment is shown with thecorners of the metal and mold frames 610 and 620 formed to have apredetermined curvature by a rounding process. Alternatively, thecorners of the metal and mold frames 610 and 620 may be formed in anyshape by a typical rounding process.

The container member 600 may be produced by forming the metal frame 610and the mold frame 620 separately, then rounding the corners of themetal and mold frames 610 and 620, and then fastening the metal and moldframes 610 and 620 together. Another method of producing the containermember 600 includes forming the metal frame 610 having the first opening610 a at the bottom thereof, rounding the corners of the metal frame610, and then forming the mold frame 620 inside the metal frame 610 byinjection molding. When the mold frame 620 is produced using injectionmolding where the metal frame 610 serves as the mold, the process ofmanufacturing the container member 600 is simplified, and the metalframe 610 is in close contact with the mold frame 620 so that the impactand stress caused by an external impact such as a drop impact can bemore effectively relieved.

Further, similar to the aforementioned first embodiment, the containermember 600 of the second embodiment may include at least one firstfastening hole 613 located in each side 611 of the metal frame 610 andat least one first protrusion 623 located on each side of the mold frame620 corresponding to the first fastening hole 613 such that the metalframe 610 may be firmly coupled to the mold frame 620.

The container member 600 may also include at least one first step 614located on each side 611 of the metal frame 610 and at least one secondprotrusion 624 located on each side of the mold frame 620 correspondingto the first step 614. Specifically, the steps 614 of the metal frame610 are located at corners of the metal frame 610 such that the metalframe 610 can be firmly coupled with the mold frame 620 regardless of adirection of the external impact applied to the metal frame 610.

In the display device according to a second embodiment, the mold frame620 may include a bottom 621 having a second opening 620 a having anarea corresponding to that of the first opening 610 a, and sides 622contacting the sides 612 of the metal frame 610. In this case, thebottom 621 of the mold frame 620 has the same thickness as thedouble-sided tape (not shown) between the bottom 611 of the metal frame610 and the display panel (not shown) such that an entire thickness ofthe display device is not increased due to the bottom 621 of the moldframe 620.

Further, when the bottom 621 of the mold frame 620 is located atportions of the display panel that correspond to the image producingdisplay region, the mold frame 620 and the buffer tape are less apt tovibrate upon external impact because the mold frame 620 and the buffertape are soft. However, since the display region of the display panelhas a plurality of elements for displaying a predetermined image, slightdamage to the display panel may reduce a contrast ratio and luminance ofthe image. As a result, the second opening 620 a is designed to have arelatively large area compared to the first opening 610 a, so that thebottom 621 of the mold frame 620 is not located at the regioncorresponding to the display region of the display panel.

Table 2 below shows the results of performing a drop test on the displaydevice including the container member 600 having the metal frame 610having the rounded corners and the mold frame 620 located inside themetal frame 610 according to the second embodiment of the presentinvention, and in particular a structure (Type 3) in which the firstopening 610 a is formed in the bottom 611 of the metal frame 610, and astructure (Type 4) in which the first opening 610 a is not formed in thebottom 611 of the metal frame 610.

Here, the method of performing the drop test is the same as in the firstembodiment, and so its description will not be repeated.

TABLE 2 Deformation Jig Rigidity Jig Drop Result Type 3 90.5 45.0 135.5Type 4 70.5 20.5 91.0

Referring to Table 2, the structure (Type 3) in which the first opening610 a is formed in the bottom 611 of the metal frame 610 got arelatively high scores compared to the structure (Type 4) in which thefirst opening 610 a is not formed in the bottom 611 of the metal frame610. Thus, it could be concluded that the structure (Type 3) in whichthe first opening 610 a is formed in the bottom 611 of the metal frame610 relieved the external impact and stress in a relatively effectivemanner.

Further, comparing the drop test results of the first embodiment withthose of the second embodiment, it could be further concluded that bothof the structure (Type 3) in which the first opening 610 a is formed inthe bottom 611 of the metal frame 610 and the structure (Type 4) inwhich the first opening 610 a is not formed in the bottom 611 of themetal frame 610 had relatively high drop performance when the corners ofthe metal frame 610 were rounded as compared to the structure of type 1and type 2 respectively where the corners were not rounded. Therefore,in addition to forming an opening in a bottom of a metal frame, roundingthe corners of the metal frame served to further protect the displaypanel within the container member.

Consequently, the display device according to a second embodimenteffectively absorbs and relieves the external impact using the containermember, which provides the space for accommodating the display panel,includes the metal frame having the first opening formed in its bottomand the mold frame located between the metal frame and the displaypanel, and in which the corners of the metal frame are rounded, therebyminimizing the deformation to the display panel caused by the externalstress.

Thus, both a container member, which has a metal frame providing a spacethat accommodates a display panel and having a bottom with a firstopening and a mold frame interposed between sides of the metal frame andthe display panel, and a display device having the container memberprevents damage to a display panel during an assembly process using thecontainer member, sufficiently reduces or eliminates impact transmittedto the display panel by an external impact such as a drop impact, andminimizes deformation of the display panel caused by an external stress,so that the container member may effectively protect display panel fromdamage.

Although a few embodiments have been shown and described, it would beappreciated by those skilled in the art that changes may be made in thisembodiment without departing from the principles and spirit of theinvention, the scope of which is defined in the claims and theirequivalents.

1. A display device, comprising: a display panel; and a containermember, the container member including: a metal frame including a spacethat accommodates the display panel, a plurality of sides and a bottomhaving a first opening; and a mold frame arranged between the sides ofthe metal frame and sides of the display panel.
 2. The display device ofclaim 1, each of the sides of the metal frame includes at least onefastening aperture, the mold frame includes a plurality of sides, eachof the sides of the mold frame includes at least one first protrusionarranged at a location that corresponds to the fastening aperture. 3.The display device of claim 1, each of the sides of the metal frameincludes at least one step, the mold frame includes a plurality ofsides, each of the sides of the mold frame includes at least one secondprotrusion arranged at a location that corresponds to the step.
 4. Thedisplay device of claim 1, wherein the metal frame further includes aplurality of rounded corners.
 5. The display device of claim 4, whereineach of the corners have a curvature.
 6. The display device of claim 1,wherein each of the sides of the metal frame have a hemmed structure. 7.The display device of claim 1, wherein the mold frame further includes abottom having a second opening having an area that corresponds to thefirst opening.
 8. The display device of claim 1, further comprising abuffer tape arranged within the first opening of the metal frame.
 9. Amethod of manufacturing a container member that accommodates a displaypanel, the method comprising: providing a metal frame having a bottomand a plurality of sides, the bottom having a first opening; and forminga mold frame on inner sides of the metal frame by injection molding. 10.The method according to claim 9, further comprising: forming at leastone fastening aperture in each of the sides of the metal frame; andforming at least one protrusion on each side of the mold frame at alocation that corresponds to the fastening aperture during saidinjection molding.
 11. The method according to claim 9, furthercomprising: forming at least one step in each of the sides of the metalframe; and forming at least one protrusion on each side of the moldframe at a location that corresponds to the step during said injectionmolding.
 12. The method according to claim 9, further comprisingrounding corners of the metal frame prior to said formation of the moldframe.
 13. The method according to claim 9, further comprising producinga hemmed structure by folding the sides of the metal frame prior to saidformation of the mold frame.
 14. A display device, comprising: a displaypanel to display an image; a metal frame including a space thataccommodates the display panel, a plurality of sides and a bottom havinga first opening; a mold frame arranged between the sides of the metalframe and sides of the display panel; and a buffer tape arranged withinthe first opening of the metal frame.
 15. The display device of claim14, wherein the metal frame includes at least one fastening aperturearranged in each of the sides, and the mold frame includes at least onefirst protrusion arranged on each side thereof to correspond to thefastening aperture.
 16. The display device of claim 14, wherein themetal frame includes at least one step arranged in each of the sides,and the mold frame includes at least one second protrusion arranged oneach side thereof to correspond to the step.
 17. The display device ofclaim 14, wherein the metal frame includes rounded corners.
 18. Thedisplay device of claim 14, wherein the sides of the metal frame have ahemmed structure.
 19. The display device of claim 14, wherein the moldframe further includes a bottom having a second opening having an areacorresponding to the first opening.
 20. The display device of claim 14,further comprising a double-sided tape arranged between the displaypanel and the bottom of the metal frame.